Failure analysis of 3D printed FZG spur gears made of AISI316L austenitic steel

This study explores the tribological behaviour 3D-printed spur gears made of AISI316L steel. The gears were tested on an FZG test bench under lubricated conditions and varied load. The effect of applied torque on scorring and resistance to pitting was investigated. After each test the mass loss of the gear was measured and the working surface of the gear teeth was examined using macrophotography and stylus profilometer. After completing the tests the working surface and the subsurface region on the cross-section of the teeth were analysed with use of the scanning electron microscopy (SEM). Numerical model of the analysed gear was prepared and used for validation of the obtained laboratory data. The results indicate that the investigated material displays different tribological behaviour compared to conventional AISI316L. The gears have shown promising performance for torques lower than 60 Nm. However, tests with a torque of 135 Nm indicated failure of the gear material, revealing pitting and scorring as well as a network of subsurface cracks propagating in the surface direction. This study highlights the need for further research on the performance of 3D-printed components under demanding conditions, aiming to bridge the gap between additive manufacturing and conventional materials in industrial applications. • FZG test results of 3D printed AISI316L spur gears are presented. • The gears have shown promising performance for torques lower than 60 Nm. • For higher loads pitting and scuffing of the gear material are the main failure mechanisms. • The numerical analysis results were corroborated through empirical studies.